Synthetic two piece induction seal products

Abstract

A two-piece induction seal for use in creating clean, safe, and secure inner seals on containers having a monolayer plastic formed from synthetic fibers with stable pore dimensions for fluid permeability while retaining dimensional stability for compression. An inductive innerseal membrane is provided having a first side and a second side thereof, with an adhesive layer at the first side of the membrane. The second side of the membrane is detachably bound to the synthetic material with a wax layer. The synthetic material is further suitable for absorbing substantially all of said wax layer when said wax layer is in liquid form.

Description

CROSS-REFERENCE TO RELATED APPLICATION[0001]This application claims priority pursuant to 35 U.S.C. 119(e) to U.S. Provisional Application No. 60 / 867,545, filed on Nov. 28, 2006 which is incorporated herein by reference in its entirety.FIELD OF THE INVENTION[0002]The present invention relates to two piece induction container seals, and more particularly to novel synthetic two piece induction seal products.BACKGROUND OF THE INVENTION[0003]A variety of two-piece induction seals have been developed. Seal products have application in the closure industry. The seal generally includes a compressing agent (e.g., a thickness of pulpboard or layers of synthetic foam) and an induction membrane layer (e.g., foil), with a wax layer between them to keep them in place during processing. The membrane layer further has an adhesive layer on its bottom surface which is generally a heat-activated adhesive layer. During bottle closure operations, the seal product is placed between the rim or other openi...

AI Technical Summary

Benefits of technology

[0008]With the induction membrane detachably bound using a wax layer, the present invention overcomes the problems of the prior art in an efficient and cost-effective manner. Through the use of a synthetic compressing agent absorbing material comprising a monolayer plastic formed from synthetic fibers with stable pore dimensions for fluid permeability while retaining dimensional stability for compression, the resulting cap inner seal presents a clean, safe and structurally sound product. As such the synthetic material may be formed with highly fibrillated polyolefin synthetic pulp fiber for uniform dimensional stability for compression with stable pore dimensions for fluid permeability which substantially completely absorbs the wax, and does not create debris that could otherwise contaminate the contents of the container.

Problems solved by technology

However, this system presents numerous disadvantages.

The pulpboard becomes a source of paper dust which can contaminate the contents of the container.

Eventually, this can cause the paper layer to seal to the synthetic foam.

Additionally, pulpboard or paper are moisture sensitive and can become distorted and altered by fluctuations in humidity levels.

A principle disadvantage of this device is that the adhesive layer which is present on the surface of the compressing agent remains tacky.

The prior art does not solve the traditional problems of contamination, because the paper layer on the foil can continue to serve as a biological growth medium.

In addition, the paper layer can present structural issues by delaminating from the foil layer and by expanding and contracting due to changes in humidity.

This seal has been found to solve some of the problems described above, but the TYVEK™ synthetic polymer does not present a uniform absorbing surface due to porosity dimensional instability.

The limitations of TYVEK™ can be attributed to the inconsistent fiber composition related to the flash spinning manufacture method used in its production that results in long fiber content.

In some instances the TYVEK™ layer melts, creating difficulty in opening the container.

However, this prior art design was not commercialized due to the inability to maintain adequate adhesion after being wax laminated.

Unfortunately a small amount of residual mineral oil remains in the film's matrix after processing.

It was determined that the mineral oil would migrate out of the film and dissolve the microcrystalline wax used to laminate the 2 piece structure resulting in premature separation of the laminate.

Alkali bases (e.g. sodium or potassium hydroxide) at higher pH levels or elevated temperatures will attack the silica filler and lead to shrinkage as the silica is removed from the sheet.

Elevated temperatures may also lead to dimensional changes with weaker bases, which is of concern in a variety of end uses.

For example alkali bleach that is typically pH 9.5 and above would be considered a typical package requirement for secondary sealing, as produced in the design, and would be of concern due to the described dimensional instability issues.

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